Drive mechanism and power tool
A reciprocating saw generally includes a housing and a motor supported by the housing. A spindle is mounted for reciprocation relative to the housing, the spindle having a front end for supporting a saw blade and being movable through a cutting stroke and a return stroke, and the cutting stroke may have a stroke length. A rotary member may be supported for rotation about a rotary axis. The saw may further include an adjusting assembly operable to adjust the stroke length of the spindle. Also, the saw may include a counterweight supported for movement relative to the housing, a movement of the counterweight substantially balancing at least a portion of movement of the spindle, and an adjusting assembly operable to adjust the movement of the counterweight.
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The present application claims the benefit of prior-filed, provisional patent application Ser. No. 60/436,428, filed Dec. 23, 2002, the contents of which is hereby incorporated by reference.
FIELD OF THE INVENTIONThe invention relates generally to power tools and, more particularly, to a drive mechanism for a power tool.
BACKGROUND OF THE INVENTIONA reciprocating power tool, such as a reciprocating saw, generally includes a housing, a motor supported by the housing, a drive mechanism and a reciprocating output member, such as a reciprocating spindle, driven by the drive mechanism. The output member supports a tool element, such as a saw blade, and is movable through a cutting stroke. Typically, the drive mechanism moves the output member through a cutting stroke having a fixed stroke length.
SUMMARY OF THE INVENTIONThe present invention provides a drive mechanism, a reciprocating device, a reciprocating power tool and a reciprocating saw which alleviates one or more independent problems with existing drive mechanisms and power tools. In some aspects and in some constructions, the invention may generally provide a reciprocating drive mechanism having a stroke length which may be adjustable to any stroke length including and between a minimum stroke length and a maximum stroke length. In some aspects and in some constructions, the invention may generally provide a counterbalance mechanism which may be adjustable to change a counterbalance force. In some aspects and in some constructions, the invention may generally provide a reciprocating mechanism having an adjustable stroke length and a counterbalance mechanism which may be adjustable to counterbalance a force caused by the reciprocating mechanism in one or more adjusted stroke lengths.
One or more independent features and independent advantages of the present invention will become apparent to those skilled in the art upon review of the following detailed description and drawings.
Before at least one construction of the invention is explained in detail, it is to be understood that the invention is not limited in its application to the details of the construction and the arrangements of components set forth in the following description or illustrated in the drawings. The invention is capable of other constructions and of being practiced or being carried out in various ways. Also, it is understood that the phraseology and terminology used herein is for the purpose of describing the illustrated construction and should not be regarded as limiting the scope of the invention. The use of “including” and “comprising” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items.
DETAILED DESCRIPTIONAs shown in
The mechanism 10 operates to generally reciprocate the spindle 25 along the spindle axis. It should be understood that the reciprocating motion may be substantially linear along the spindle axis. The saw 15 may also include a mechanism (not shown) to provide a non-linear (i.e., orbital motion, rocker motion, etc.) reciprocating motion for the spindle 25 and for the tool supported by the spindle 25.
In the illustrated construction, the drive gear 50 is larger than the adjusting gear 55 and can be connected to the shaft 45 in many different ways. For example, the drive gear 50 could be shrunk on to the shaft 45 or keyed to the shaft 45. The motor 36 includes a drive pinion 56 or other drive member which engages the drive gear 50 to produce rotation at the desired speed. The drive engagement between drive pinion 56 and the drive gear 50 may be provided by a helical gear arrangement, a worm gear arrangement, bevel gear arrangement, etc. The housing 20 supports at least one end of the drive shaft 45 so that the shaft 45 remains free to rotate about the rotary axis 1-1 but is unable to translate.
The arm member 30 includes a drive end 60, a narrow neck region, and a spindle end 65. The neck region connects the drive end 60 to the spindle end 65. In the construction illustrated in
The bearing member 70 further includes an inner race 75, an outer race 80, and a cage member retaining roller members (not shown). The outer race 80 fits snuggly within the drive end 60 of the arm member 30. The inner race 75 defines a tab region 85 that facilitates attachment of the arm member 30 to the adjusting member 40 and to the drive gear 50. The tab region 85 projects into the opening defined by the inner race 75. The tab member 85 further defines an attachment hole 90 positioned along an eccentric axis 3-3.
The adjusting member 40, illustrated in
The knob member 100 further includes a grip portion 105, an external gear portion 110, and an internal gear portion 115, shown in
A bore 120 extending at least partially through the knob member 100 allows the knob member 100 to slide along the drive shaft 45. Concentric with the bore 120 is the internal gear portion 115 extending along the bore 120 to a depth. The internal gear portion 115 is selectively engageable with the adjusting gear 55 located on the drive shaft 45. The depth of the internal gear portion 115 is less than the length of the external gear portion 110 to allow the internal gear portion 115 to disengage the adjusting gear 55 while the external gear portion 110 remains engaged with the arcuate gear 95. When the internal gear portion 115 is engaged, the knob member 100 rotates with the drive shaft 45, rotating the arcuate gear 95 and the bearing inner race 75 in unison.
As shown in
The spindle end 65 of the arm member 30 connects to the spindle 25 as shown in
In operation, the knob member 100 selectively engages the adjusting gear 55 preventing or allowing adjustment of the stroke length of the spindle 25. To adjust the stroke length, in the illustrated construction, a user pulls the knob member 100 away from the adjusting gear 55 of the rotary member 35. Once the inner gear 115 of the knob member 100 disengages the adjusting gear, the knob member 100 is free to rotate independently of the rotary member 35. Rotation of the knob member 100 in a first, in the illustrated construction, clockwise direction results in increased or longer stroke lengths, and rotation in a second, in the illustrated construction, counter-clockwise rotation results in reduced or shorter stroke lengths.
Once the desired stroke length of the spindle 25 is set, the user pushes the knob member 100 back towards the adjusting gear 55 until the adjusting gear 55 engages the knob member 100 inner gear portion 115. Once engaged, the adjusting member 40 is rotatably connected to the rotary member 35. Rotation of the rotary member 35 about the rotary axis 1-1 results in a reciprocating motion having the desired stroke length at the spindle 25.
Referring now to
In the illustrated construction, rotation of the knob member 100 toward its first or extreme clockwise position results in a corresponding movement of the bearing center axis 2-2 away from the rotary axis 1-1. The further the bearing center axis 2-2 is from the rotary axis 1-1 the larger the stroke length at the spindle end 65 of the arm member 30.
Referring now to
Referring to
An indicator assembly (not shown) may be provided to indicate to the user the selected stroke length of the spindle 25. The indicator assembly may include a first indicator member (not shown) provide by, for example, the knob member 100 and at least one second indicator member (not shown) provided by, for example, a portion of the housing 20 adjacent to the knob member 100. Alignment of the first indicator member with a second indicator member may indicate a first stroke length, and alignment of the first indicator member with another second indicator member (or mis-alignment of the first indicator member and the first-mentioned second indicator member) may indicate a second stroke length.
A detent arrangement (not shown) may be provided to easily position the knob member 100 in a position corresponding to a selected stroke length. Such a detent arrangement may include a first detent member (not shown) provided by, for example, the knob member 100 and at least one second detent member (not shown) provided by, for example, a portion of the housing 20 adjacent to the knob member 100. Positioning of the first detent member in a second detent member may correspond to a first stroke length, and positioning of the first indicator member in another second indicator member may correspond to a second stroke length.
As with the construction of
In the alternate construction of the mechanism 10′, the drive shaft 140 of the rotary member 35, best illustrated in
In addition, a longer screw 145 is used, allowing the screw 145 to pass through the drive gear 50 so that it can be connected to the counterweight assembly 135. The screw 145 attaches the arcuate gear 95 to the bearing inner race 75 in a manner that maintains a substantially fixed relationship between the two components. The screw 145 extends along the eccentric axis 3-3 and through the drive gear 50 so that the attached arcuate gear 95 and inner race 75 are free to rotate about the eccentric axis 3-3 and are prevented from translating. The screw 145 also connects to the counterweight assembly 135 and moves the counterweight assembly 135 in response to movement of the arcuate member 95.
In the illustrated construction, the counterweight assembly 135 includes a crank arm 150, a link arm 155, and a weight arm 160. The crank arm 150 has two ends, a pivot end 165, and a link end 170. The pivot end 165 attaches to the end of the screw 145 that extends beyond the drive gear 50 such that the crank arm 150 maintains a fixed relationship with the arcuate gear 95. Rotation of the arcuate gear 95 produces a corresponding rotation of the crank arm 150 about the eccentric axis 3-3.
The link arm 155 includes two connection ends, the first being pivotally connected to the crank arm 150 at the link end 170, and the second being pivotally connected to the weight arm 160. The weight arm 160 is pinned to the drive gear 50 near the center of the arm 160 to define two ends, a crank end 175 and a mass end 180. The crank end 175 of the weight arm 160 pivotally connects to the link end 170, while the mass end 180 of the weight arm 160 is free to move in response to movement of the arcuate gear 95. The crank arm 150, link arm 155 and weight arm 160 are sized and arranged so that a force of the mechanism 10′ remains substantially balanced in relation to the rotary axis 1-1 regardless of the stroke length.
Referring to
Compounding the imbalance at longer stroke lengths is the position of the arcuate gear 95. The center of mass of the arcuate gear member 95 is shifted in the same direction as the center of mass of the arm member 30 increasing the imbalance. To counteract the imbalance, the mass end 180 of the weight arm 160 is extended in substantially the opposite direction to produce a substantially equal but opposite counterbalancing force during rotation.
Referring next to
Comparing
With the exception of the counterweight assembly 135, the construction of the mechanism 10′ illustrated in
It should be understood that, in some aspects and in some constructions (not shown), the mechanism 10′ may include only an adjustable counterweight assembly (similar to the counterweight assembly 135). In such constructions and for such aspects, the counterweight assembly alone (e.g., the resulting counterbalance force, movement, range of movement, stroke length alone of the counterweight assembly) may be adjustable. In such constructions and for such aspects, the stroke length of the spindle 25 may not be adjustable.
It should also be understood that, in some aspects and in some constructions (not shown), the mechanism 10′ may include an independently adjustable counterweight assembly (similar to the counterweight assembly 135). In such constructions and for such aspects, the counterweight assembly alone (e.g., the resulting counterbalance force, movement, range of movement, stroke length alone of the counterweight assembly) may be adjustable independently of any adjustment of the stroke length of the spindle 25.
In addition, it should be understood that, in some aspects and in some constructions (not shown), another counterweight assembly may be provided, and such another counterweight assembly may or may not be adjustable. For example, such another counterweight assembly may include a counterweight member reciprocating along the axis of the spindle or along an axis parallel to the spindle. Such a counterweight member may be driven in a manner similar but opposite to the spindle 25 by, for example, an arm member (similar to the arm member 30), and the counterweight assembly may be adjustable in a manner similar to the spindle 25.
The mechanism 10′ may include an indicator assembly (not shown) to indicate the selected stroke length of the spindle 25 or the configuration of the counterweight assembly 135 (e.g., the resulting counterbalance force, movement, range of movement, stroke length, etc. of the counterweight assembly 135). The mechanism 10′ may also include a detent arrangement (not shown) to easily position the knob member 100 in a position corresponding to a selected configuration (e.g., stroke length of the spindle 25 or the configuration of the counterweight assembly 135 (e.g., the resulting counterbalance force, movement, range of movement, stroke length, etc. of the counterweight assembly 135)).
Assembly of the construction of
In the illustrated construction, before assembling any components into the housing 20, the counterweight assembly 135 is pre-assembled. The link arm 155 connects at one end to the crank arm 150 and at the other end to the weight arm 160. The link arm 155 connections are pivotal to allow the link arm 155 to pivot relative to both the weight arm 160 and the crank arm 150. Next, the weight arm 160 is pivotally attached to the drive gear 50 so that the weight arm 160 remains free to pivot about the attachment point. The adjusting gear 55 along with the drive gear/counterweight assembly 50/135 connect to the drive shaft 140.
Assembly of the components into the housing 20 begins with the insertion of the drive shaft end into a support provided within the housing 20. The support (not shown) positions the drive shaft 140 so that the counterweight assembly 135 is free to rotate without contacting the housing 20 or other components and may include one or more bearing members (not shown) to reduce friction between the drive shaft 140 and the housing 20 during rotation of the drive shaft 140. Next, the arm member 30, including the bearing 70, is positioned. The spindle end 65 connects to the spindle 25, which is supported by the housing 20 in a manner that allows only reciprocating motion. The drive end 60 passes over the drive shaft 140 allowing the rotary axis 1-1 to pass within the opening defined by the bearing inner race 75.
The arcuate gear member 95 is positioned so that its center axis is coincident with the eccentric axis 3-3 and the bearing center axis 2-2 passes through the opening defined by the arcuate gear 95. The screw 145 connects the arcuate gear 95 to the bearing inner race 75, extends through the drive gear 50, and engages the crank arm 150 of the counterweight assembly 135 to fix the relationship between the bearing inner race 75, arcuate gear 95, and crank arm 150. The screw 145, by passing through the drive gear 50, also fixes the position of the eccentric axis 3-3 relative to the drive gear 50, thereby allowing rotation but no translation.
The knob member 100 slides over the drive shaft 140, engages the arcuate gear member 95, and selectively engages the adjusting gear 55. A snap ring fits on the drive shaft 140 to confine the knob member 100 to the shaft 140 and complete the assembly.
Referring to
An arm member 30A connects to the spindle 25 at the end opposite the blade or tool. The arm member 30A transfers the rotary motion of the rotary member 35 into reciprocating motion of the spindle 25. The second end of the arm member 30A connects to an adjusting member 40A along a movable eccentric axis E-E.
The rotary member 35 is supported by the housing 20 and driven by an electric motor or other drive device. The rotary member 35 rotates about a rotary axis R-R that is fixed relative to the housing 20. Generally, a gear directly or indirectly driven by a motor drives the rotary member 35. The adjusting member 40A interconnects the arm member 30A and the rotary member 35 to facilitate the conversion of rotary motion to linear motion, while allowing the user to vary the reciprocating stroke length of the spindle 25.
In the illustrated construction, the adjusting member 40A includes a triangular plate 200 that defines three axis, one near each apex. The first axis is the eccentric axis E-E. The arm member 30A connects to the triangular plate 200 along the eccentric axis E-E such that the triangular plate 200 translates the rotational motion of the rotary member 35 to reciprocating motion at the spindle 25.
The second apex pivotally connects to the rotary member 35 along the second axis S-S. The second axis S-S is spaced a distance from the rotary axis R-R such that rotation of the rotary member 35 causes the second axis S-S to orbit the rotary axis R-R. A first link member 205 pivotally connects to the triangular plate 200 along the third axis T-T. The first end of the link 205 connects to the triangular plate 200 and the second end movably connects to an adjusting knob 210.
While a triangular plate 200 is illustrated in
The adjusting knob 210 of
In operation, the knob member 210 is positioned to achieve the desired reciprocating stroke length of the spindle 25. The knob position locks the position of the second end of the link member 205 relative to the housing 20 such that the first end of the link member 205 is free to pivot along an arc having its center at the end of the link 205. The first end of the link member 205, which attaches to the triangular plate 200 through the third axis T-T, travels along a portion of a circle having a radius defined by the length of the link member 205 and a center point defined by the position of the knob 210.
The motor operates to rotate the rotary member 35 and the triangular plate 200 that is attached to the rotary member 35. The second axis S-S of the triangular plate 200 orbits the rotary axis R-R in response to rotation of the rotary member 35. The movement of the second axis S-S (orbiting around the rotary axis R-R) combined with the restrained movement of the third axis T-T (along a portion of a circle) results in the desired reciprocating motion of the eccentric axis E-E. The eccentric axis E-E reciprocates forwardly and reawardly as well as translates upwardly and downwardly. Guides 220 supporting the spindle 25 and/or guiding the arm member 30A produce the desired reciprocating motion at the spindle 25.
In the illustrated “maximum” stroke configuration, a relatively greater portion of the rotation of the rotary member 35 is converted to movement of the arm member 30A and of the spindle 25 along the spindle axis (i.e., a relatively longer stroke length). In comparison, in the illustrated configuration, a relatively lesser portion of the rotation of the rotary member 30A is converted to movement of the arm member 30A transverse to the axis of the spindle 25.
In the illustrated “minimum” stroke configuration, a relatively lesser portion of the rotation of the rotary member 35 is converted to movement of the arm member 30A and of the spindle 25 along the spindle axis (i.e., a relatively shorter stroke length). In comparison, in the illustrated configuration, a relatively greater portion of the rotation of the rotary member 30A is converted to movement of the arm member 30A transverse to the axis of the spindle 25.
It should be understood that, in other constructions (not shown), the mechanism 10A may also include a counterweight assembly (not shown), and the counterweight assembly may or may not be adjustable. Also, in other constructions (not shown), the mechanism 10A may be used to adjust such a counterweight assembly rather than adjusting the stroke length of the spindle 25. In addition, in other constructions (not shown), the mechanism 10A may adjust the counterweight assembly and the stroke length of the spindle 25. Further, in other constructions (not shown), a separate adjusting assembly (not shown) may be provide to adjust the counterweight assembly.
The mechanism 10A may include an indicator assembly (not shown) to indicate the selected stroke length of the spindle 25 or the configuration of the counterweight assembly (e.g., the resulting counterbalance force, movement, range of movement, stroke length, etc. of the counterweight assembly), if provided. The mechanism 10A may also include a detent arrangement (not shown) to easily position the knob member 210 in a position corresponding to a selected configuration (e.g., stroke length of the spindle 25 or the configuration of the counterweight assembly (e.g., the resulting counterbalance force, movement, range of movement, stroke length, etc. of the counterweight assembly), if provided).
In the illustrated construction, a housing 20 supports a rotary element 35 for rotation and a spindle 25 for reciprocation. The rotary element 35 is a gear that is directly, or indirectly, driven by a motor or other rotating device. The rotary member 35 defines a rotary axis R-R that is fixed relative to the housing 20.
An eccentric axis E-E passes through the rotary member 35 at a distance from the rotary axis R-R such that rotation of the rotary member 35 moves the eccentric axis E-E along an orbital path around the rotary axis R-R. In the illustrated construction, a first link member 225 includes a first end 230 that pivotally connects to the rotary member 35 along the eccentric axis E-E such that the first end 230 orbits the rotary axis R-R in response to rotation of the rotary member 35. The second end 235 of the first link member 225 defines a junction 238.
An adjusting member 40B including a second link 240 having a first end 245 pivotally connects to the first link member 225 at the junction 238. A second end 250 of the second link 240 pivotally connects to an adjusting gear 255. The adjusting gear 255 is fixed relative to the housing 20 and rotatable about an adjusting axis A-A. Rotation of the gear 255 moves the second end 250 of the second link 240.
During operation, the adjusting gear 255 remains fixed as does the location of the second end 250 of the second link member 240. This constrains the movement of the first end 245 of the second link member 240, and the junction 238, to movement along a circular arc having a radius defined by the length of the second link member 240 and a center defined by the position of the second end 250 of the second link member 240.
Completing the adjusting member 40B in the construction of
An arm member 30B is also attached to the junction 238. A first end 265 of the arm member 30B is pivotally connected to the first end 245 of the second link member 240 and the second end 235 of the first link member 225 at the junction 238. Thus, the two link members 225, 240 and the arm member 30B are free to pivot relative to one another and move relative to the housing 20. A second end 270 of the arm member 30B pivotally connects to the first end of the spindle 25 and drives the spindle 25 in a reciprocating motion as described above.
In operation, the knob gear 260 is rotated until the adjusting gear 255 is in the position that produces the desired stroke length of the spindle 25. The rotary member 35 is rotated by a motor or engine such that the eccentric axis E-E and first end 230 of the first link member 225 orbit the rotary axis R-R. Because the position of the second end 250 of the second link member 240 is fixed, the junction 238 located at the second end 250 of the second link member 240 is constrained to travel along the circular arc defined by the second link member 240. Thus, the junction 238 reciprocates along a partial circular arc. The arm member 30B, attached at one end to the junction 238 and at the other end to the spindle 25, reciprocates in response to the rotation of the rotary member 35. The first end 265 of the arm member 30B follows the circular arc along with the junction 238, while the second end 270 follows the path defined for the spindle 25. Generally, this is a linear reciprocating path.
Reciprocating saws are used to cut a variety of products and a variety of materials, such as metal conduits and pipes, plastic or PVC components, wood, shingles, dry wall, plaster, etc. An adjustable stroke length, controllable by the user, may allow a user to efficiently cut only the desired components and to not cut other components. An adjustable stroke length may be used to change the cutting speed of the saw, thereby making it cut different materials more efficiently.
In some aspects and in some constructions, infinite adjustment of the stroke length (including and between a minimum stroke length and a maximum stroke length) or of the configuration of the counterweight assembly may be provided. In some aspects and in some constructions, the adjustment of the configuration of the illustrated mechanisms may be accomplished during operation of the mechanism (e.g., with the motor operating). In some aspects and in some constructions, the adjustment of the configuration of the illustrated mechanisms may be accomplished without disassembly of the mechanisms. When the stroke length of the spindle 25 is adjusted, the magnitude and frequency of the vibration caused by the drive mechanism may change, and, in some aspects and in some aspects, the counterweight assembly may be adjusted to counterbalance the different forces caused by the adjustment of the stroke length.
It should be understood that the terms “maximum”, “minimum” or “extreme” as used herein are not intended to indicate the maximum or minimum stroke length or most extreme position possible. Rather, the terms are meant to convey the maximum or minimum position or stroke length of the construction illustrated with greater maximums or extremes and lesser minimums still being possible. Therefore, the terms maximum, minimum or extreme should not be read as limiting the scope of the invention to the stroke lengths or positions illustrated or described herein.
It should also be understood that the terms “forward” or “extended” and “rearward” or “retracted” as used herein are not intended to indicate the forwardmost or rearwardmost position possible. Rather, the terms are meant to convey a forward or extended position or a rearward or retracted position, respectively, in the construction illustrated with farther forward and rearward positions still being possible. Therefore, these terms should not be read as limiting the scope of the invention to the positions illustrated or described herein.
Although particular constructions of the present invention have been shown and described, other alternative constructions will be apparent to those skilled in the art and are within the intended scope of the present invention. Thus, the present invention is to be limited only by the claims.
Claims
1. A reciprocating saw comprising:
- a housing;
- a motor supported by the housing;
- a spindle supported for reciprocation relative to the housing, the spindle having a front end for supporting a saw blade and being movable through a cutting stroke and a return stroke, the cutting stroke and the return stroke having a stroke length;
- a spindle drive mechanism connected between the motor and the spindle and operable to reciprocate the spindle;
- a counterweight supported for movement relative to the housing, a movement of the counterweight in a direction substantially opposite a movement of the spindle substantially balancing at least a portion of the movement of the spindle;
- a counterweight drive mechanism operable to move the counterweight relative to the housing; and
- an adjustment assembly having an actuator extending outwardly through the housing and being operable to adjust an extent of movement of the counterweight relative to the housing in response to adjusting the stroke length of the spindle.
2. The reciprocating saw of claim 1, wherein the counterweight has a range of movement relative to the housing, and wherein the adjustment assembly is operable to adjust the range of movement of the counterweight relative to the housing.
3. The reciprocating saw of claim 2, wherein the counterweight has a stroke length defining the range of movement, and wherein the adjustment assembly is operable to adjust the stroke length of the counterweight.
4. The reciprocating saw of claim 3, wherein, in a first condition of the adjustment assembly, the counterweight has a first stroke length, and wherein, in a second condition of the adjustment assembly, the counterweight has a second stroke length, the second stroke length being different than the first stroke length.
5. The reciprocating saw of claim 3, wherein the counterweight has a center of mass, the center of mass being movable relative to the housing between a first position and a second position, a distance between the first position and the second position being the stroke length of the counterweight.
6. The reciprocating saw of claim 5, wherein the adjustment assembly is operable to adjust the distance between the first position and the second position.
7. The reciprocating saw of claim 1, wherein the counterweight drive mechanism includes
- a rotary member supported for rotation relative to the housing and drivable by the motor, and
- a drive arm connected between the rotary member and the counterweight, rotation of the rotary member causing the drive arm to move the counterweight relative to the housing.
8. The reciprocating saw of claim 7, wherein the rotary member is rotatable about a rotary axis, and wherein the drive arm is connected to the rotary member along an eccentric axis offset from the rotary axis.
9. The reciprocating saw of claim 7, wherein the spindle drive mechanism includes the rotary member and a spindle drive arm connected between the rotary member and the spindle, rotation of the rotary member causing the spindle drive arm to reciprocate the spindle.
10. The reciprocating saw of claim 1, wherein the spindle has a stroke length relative to the housing, and wherein said reciprocating saw further comprises a spindle adjustment assembly operable to adjust the stroke length of the spindle.
11. The reciprocating saw of claim 10, wherein the adjustment assembly provides at least a portion of the spindle adjustment assembly.
12. A reciprocating saw comprising:
- a housing;
- a motor supported by the housing;
- a spindle supported for reciprocation relative to the housing, the spindle having a front end for supporting a saw blade and being movable through a cutting stroke and a return stroke, the cutting stroke having a stroke length;
- a spindle drive mechanism connected between the motor and the spindle and operable to reciprocate the spindle;
- a spindle adjustment assembly operable to adjust the stroke length of the spindle;
- a counterweight supported for movement relative to the housing, a movement of the counterweight in a direction substantially opposite a movement of the spindle substantially balancing at least a portion of the movement of the spindle;
- a counterweight drive mechanism operable to move the counterweight relative to the housing; and
- a counterweight adjustment assembly having an actuator extending outwardly through the housing and being operable to adjust an extent of the movement of the counterweight relative to the housing in response to adjusting the stroke length of the spindle.
13. The reciprocating saw of claim 12, wherein the spindle adjustment assembly provides at least a portion of the counterweight adjustment assembly.
14. The reciprocating saw of claim 12, wherein the counterweight adjustment assembly provides at least a portion of the spindle adjustment assembly.
15. The reciprocating saw of claim 12, wherein the spindle drive mechanism provides at least a portion of the counterweight drive mechanism.
16. The reciprocating saw of claim 12, wherein the counterweight drive mechanism provides at least a portion of the spindle drive mechanism.
17. The reciprocating saw of claim 16, wherein the counterweight drive mechanism includes
- a rotary member supported for rotation relative to the housing and drivable by the motor, and
- a drive arm connected between the rotary member and the counterweight, rotation of the rotary member causing the drive arm to move the counterweight relative to the housing.
18. The reciprocating saw of claim 17, wherein the spindle drive mechanism includes the rotary member and a spindle drive arm connected between the rotary member and the spindle, rotation of the rotary member causing the spindle drive arm to reciprocate the spindle.
19. A reciprocating saw comprising:
- a housing;
- a motor supported by the housing;
- a spindle mounted for reciprocation relative to the housing, the spindle having a front end for supporting a saw blade and being movable through a cutting stroke and a return stroke, the cutting stroke having a stroke length;
- a rotary member supported for rotation about a rotary axis;
- an adjusting assembly adjustably connected with the rotary member, the adjusting assembly defining an eccentric axis at a position relative to the rotary axis, the position of the eccentric axis being adjustable relative to the rotary axis to adjust the stroke length of the spindle;
- an arm member having a drive end connected to the rotary member along the eccentric axis and a spindle end connected to the spindle; and
- a bearing connected to the drive end of the arm member, the bearing having an inner race and an outer race, the outer race being connected to the arm member, the eccentric axis intersecting the inner race.
20. The reciprocating saw of claim 19, wherein the arm member is pivotally connected to the rotary member.
21. The reciprocating saw of claim 19, wherein the eccentric axis is parallel to the rotary axis and spaced a distance from the rotary axis, the distance being adjustable between a first distance and a second distance.
22. The reciprocating saw of claim 19, further comprising a counterweight assembly supported for movement during reciprocation of the spindle to substantially balance at least the spindle.
23. The reciprocating saw of claim 22, wherein the counterweight has a counterweight stroke length, and wherein said reciprocating saw further comprises a counterweight adjustment assembly operable to adjust the counterweight stroke length.
24. The reciprocating saw of claim 23, wherein the counterweight has a center of mass, the counterweight stroke length being defined between a first position of the center of mass and a second position of the center of mass.
25. A reciprocating saw comprising:
- a housing;
- a motor supported by the housing;
- a spindle mounted for reciprocation relative to the housing, the spindle having a front end for supporting a saw blade and being movable through a cutting stroke and a return stroke, the cutting stroke having a stroke length;
- a rotary member supported for rotation about a rotary axis;
- an adjusting assembly adjustably connected with the rotary member, the adjusting assembly defining an eccentric axis at a position relative to the rotary axis, the position of the eccentric axis being adjustable relative to the rotary axis to adjust the stroke length of the spindle; and
- an arm member having a drive end connected to the rotary member along the eccentric axis and a spindle end connected to the spindle;
- wherein the adjusting assembly further includes an arcuate gear having a center axis, the center axis being coincident with the eccentric axis, the arcuate gear movably engaging the rotary member.
26. The reciprocating saw of claim 25, further comprising a fastener disposed along the eccentric axis, the fastener fixedly connecting the arcuate gear to the drive end of the arm member, the fastener pivotally connecting the arcuate gear to the rotary member.
27. the reciprocating saw of claim 25, wherein the adjusting assembly further includes an actuator operatively engaged with the arcuate gear and selectively engageable with the rotary member, wherein, when the actuator is engaged with the rotary member, the stroke length is fixed and, when the actuator is disengaged from the rotary member, adjustment of the actuator adjusts the stroke length of the spindle.
28. A reciprocating saw comprising:
- a housing;
- a motor supported by the housing;
- a spindle mounted for reciprocation relative to the housing, the spindle having a front end for supporting a saw blade and being movable through a cutting stroke and a return stroke, the cutting stroke having a stroke length;
- a rotary member supported for rotation about a rotary axis;
- an adjusting assembly adjustably connected with the rotary member, the adjusting assembly defining an eccentric axis at a position relative to the rotary axis, the position of the eccentric axis being adjustable relative to the rotary axis to adjust the stroke length of the spindle; and
- an arm member having a drive end connected to the rotary member along the eccentric axis and a spindle end connected to the spindle;
- wherein the rotary member further includes a drive element connected to a drive shaft, and an adjusting element connected to the drive shaft.
29. The reciprocating caw of claim 28, wherein the drive element is a gear rotatable about the rotary axis.
30. The reciprocating saw of claim 28, wherein the adjusting element is a gear fixed to the drive shaft.
31. A reciprocating device comprising:
- a housing;
- a motor supported by the housing;
- a spindle supported for reciprocation relative to the housing, the spindle having a front end for supporting a saw blade and being movable through a cutting stroke and a return stroke, the cutting stroke and the return stroke having a stroke length;
- a spindle drive mechanism connected between the motor and the spindle and operable to reciprocate the spindle;
- a counterweight supported for movement relative to the housing, a movement of the counterweight in a direction substantially opposite a movement of the spindle substantially balancing at least a portion of the movement of the spindle;
- a counterweight drive mechanism operable to move the counterweight relative to the housing; and
- an adjustment assembly having an actuator extending outwardly through the housing and being operable to adjust an extent of movement of the counterweight relative to the housing in response to adjusting the stroke length of the spindle.
32. the reciprocating device of claim 31, wherein the counterweight has a range of movement relative to the housing, and wherein the adjustment assembly is operable to adjust the range of movement of the counterweight relative to the housing.
33. The reciprocating device of claim 32, wherein the counterweight has a stroke length defining the range of movement, and wherein the adjustment assembly is operable to adjust the stroke length of the counterweight.
34. the reciprocating device of claim 33, wherein the counterweight has a center of mass, the center of mass being movable relative to the housing between a first position and a second position, a distance between the first position and the second position being the stroke length of the counterweight.
35. the reciprocating device of claim 34, wherein the adjustment assembly is operable to adjust the distance between the first position and the second position.
36. The reciprocating device of claim 32, wherein, in a first condition of the adjustment assembly, the counterweight has a first stroke length, and wherein, in a second condition of the adjustment assembly, the counterweight has a second stroke length, the second stroke length being different than the first stroke length.
37. The reciprocating device of claim 31, wherein the counterweight drive mechanism includes
- a rotary member supported for rotation relative to the housing and drivable by the motor, and
- a drive arm connected between the rotary member and the counterweight, rotation of the rotary member causing the drive arm to move the counterweight relative to the housing.
38. The reciprocating device of claim 37, wherein the rotary member is rotatable about a rotary axis, and wherein the drive arm is connected to the rotary member along an eccentric axis offset from the rotary axis.
39. The reciprocating device of claim 37, wherein the spindle drive mechanism includes the rotary member and a spindle drive arm connected between the rotary member and the spindle, rotation of the rotary member causing the spindle drive arm to reciprocate the spindle.
40. The reciprocating device of claim 31, wherein the spindle has a stroke length relative to the housing, and wherein said reciprocating device further comprises a spindle adjustment assembly operable to adjust the stroke length of the spindle.
41. the reciprocating device of claim 40, wherein the adjustment assembly provides at least a portion of the spindle adjustment assembly.
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Type: Grant
Filed: Dec 22, 2003
Date of Patent: Feb 9, 2010
Patent Publication Number: 20040187324
Assignee: Milwaukee Electric Tool Corporation (Brookfield, WI)
Inventors: Thomas P. James (Oconomowoc, WI), Roger D. Neitzell (North Prairie, WI), David A. Hempe (Wauwatosa, WI)
Primary Examiner: Hwei-Siu C Payer
Attorney: Michael Best & Friedrich LLP
Application Number: 10/742,969
International Classification: B27B 19/04 (20060101);